Oil Well Perforators

ABSTRACT

An oil and gas well shaped charge perforator capable of providing an exothermic reaction after detonation is provided, comprising a housing (2), a high explosive (3), and a reactive liner (6) where the high explosive is positioned between the reactive liner and the housing. The reactive liner (6) is produced from a reactive composition which is capable of sustaining an exothermic reaction during the formation of the cutting jet. The composition is a pressed i.e. compacted particulate composition comprising at least two metals, wherein one of the metals is present as spherical particulate, and the other metal is present as a non-spherical particulate. There may also be at least one further metal, which is not capable of an exothermic reaction with the reactive composition, present in an amount greater than 10% w/w of the liner. To aid consolidation a binder may also be added.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No.16/855,713 filed Apr. 22, 2020, U.S. patent application Ser. No.13/811,331 filed Jan. 21, 2013, International Application No.PCT/GB2011/001119 filed Jul. 26, 2011, and Great Britain PatentApplication No. 1012716.5 filed Jul. 29, 2010, the contents of each ofwhich are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to a reactive shaped charge liner for aperforator for use in perforating and fracturing subterranean wellcompletions. The invention also relates to perforators and perforationguns comprising said liners, and methods of using such apparatus.

BACKGROUND OF THE INVENTION

By far the most significant process in carrying out a well completion ina cased well is that of providing a flow path between the productionzone, also known as a formation, and the well bore. Typically, theprovision of such a flow path is carried out by using a perforator,initially creating an aperture in the casing and then penetrating intothe formation via a cementing layer. This process is commonly referredto as a perforation. Typically, the perforator will take the form of ashaped charge. In the following, any reference to a perforator, unlessotherwise qualified, should be taken to mean a shaped charge perforator.

A shaped charge is an energetic device made up of a housing within whichis placed a liner, typically a metallic liner. The liner provides oneinternal surface of a void, the remaining surfaces being provided by thehousing. The void is filled with an explosive which, when detonated,causes the liner material to collapse and be ejected from the casing inthe form of a high velocity jet of material. This jet impacts upon thewell casing creating an aperture and the jet then continues to penetrateinto the formation itself, until the kinetic energy of the jet isovercome by the material in the formation. Generally, a large number ofperforations are required in a particular region of the casing proximateto the formation. To this end, a so-called perforation gun is deployedinto the casing by wireline, coiled tubing or any other technique knownto those skilled in the art. The gun is effectively a carrier for aplurality of perforators, which perforators may be of the same ordiffering output.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided areactive oil and gas well shaped charge perforator liner comprising areactive composition of at least two metals wherein the liner is acompacted particulate composition comprising a spherical metalparticulate and a non-spherical metal particulate. By reactive, we meanthat the spherical metal particulate and the non-spherical metalparticulate are together capable of an exothermic reaction to form anintermetallic compound, upon detonation of an associated shaped chargedevice.

There are a number of intermetallic alloying reactions that areexothermic and find use in pyrotechnic applications. For example, thealloying reaction between aluminium and palladium releases 327 cals/gand the aluminium/nickel system, producing the compound Ni—Al, releases329 cals/g (2290 cals/cm³). For comparison, on detonation, TNT gives atotal energy release of about 2300 cals/cm³, so the reaction is ofsimilar energy density to the detonation of TNT, but of course with nogas release. The heat of formation for Ni—Al is about 17000 cal/mol at293 degrees Kelvin and is due to the new bonds formed between twodissimilar metals.

In a conventional shaped charge, energy is generated by the directimpact of the high kinetic energy of the jet. Reactive jets, on theother hand, comprise a source of additional heat energy, which isavailable to be imparted into the target substrate (thereby causing moredamage in the rock strata compared with non-reactive jets). Rock strataare typically porous and comprise hydrocarbons (gas and liquids) and/orwater in said pores. In a shaped charge comprising a reactive lineraccording to the invention, the fracturing is caused by direct impact ofthe jet and also by a heating effect from the exothermic reactivecomposition. This heating effect imparts further damage by physicalmeans, for example due to the rapid heating and concomitant expansion ofthe fluids present in the oil and/or gas well completion. This increasesthe pressure of the fluids, thereby causing the rock strata to crack.There may also be some degree of chemical interaction between thereactive composition and the materials in the completion. The increasedfracturing increases the total penetrative depth and volume availablefor oil and gas to flow out of the strata. Clearly the increase in depthand width of the hole leads to larger hole volumes and a concomitantimprovement in oil or gas flow, i.e. a bigger surface area of the holevolume from which the fluid may flow.

In order for a metal particulate composition to be suitable for use in ashaped charge liner, it is desirable that the intermetallic reaction canbe shock-induced at an appropriate threshold. An empirical andtheoretical study of the shock-induced chemical reaction of nickel andaluminium powder mixtures shows that the threshold pressure for reactionis about 14 GPa for spherical particulate compositions. This pressure iseasily obtained in the shock wave of modern explosives used in mostshaped charge applications, and so Ni—Al can be used in a shaped chargeliner to give a reactive, high temperature jet. The jet temperature hasbeen estimated to be 2200 degrees Kelvin. The Pd—Al system is alsosuitable for use in a shaped charge liner. However, palladium is anexpensive platinum group metal and hence, the nickel-aluminium systemhas significant economic advantages.

It is also desirable that the maximum amount of energy possible isderived from the liner, by ensuring that the intermetallic reaction goesto completion, close to completion or as close to completion aspossible.

The effect of the particle sizes of the component metals on theproperties of the resultant shaped charge jet is known to be animportant factor for obtaining good performance. Micron and nanometricsize aluminium and nickel powders are both available commercially andtheir mixtures undergo a rapid, self-supporting exothermic reaction. Ahot Ni—Al jet of this type is highly reactive to a range of targetmaterials; hydrated silicates in particular are attacked vigorously.

Despite the use of micron and sub-micron particles, however, theinventors have found that—in some liner applications—the intermetallicreaction does not always go to completion. As a result, the availableenergy from the intermetallic reaction is not completely extracted andhence, the fracturing and damage is not optimized. Moreover, in someapplications (most particularly in the case of smaller shaped charges)it has been observed that enhanced hole penetration effects are reduced.This is thought to be because, in certain liner/explosive chargeconfigurations (such as, for example, configurations implemented insmaller shaped charges), the reaction may not have run to completionthroughout the available volume of the liner, which may in turn bebecause a particular geometry leads to non-uniform behaviour in theliner. In other words, in certain regions of the liner, the activationthreshold may not have been exceeded and the intermetallic reaction maynot have occurred.

The above mentioned activation threshold may simply relate to anactivation pressure (more specifically a shock pressure), but theactivation threshold is more likely to relate to a combination offactors, such as, for example, pressure, deformation and/or thermalfactors. More generally, the activation threshold relates to the totalenergy imparted to the system and can be considered to be an activationenergy. The skilled person will realize, of course, that the physicaland chemical behaviour of a shaped charge liner in use is complex, andthe invention is not intended to be limited by any explanation onactivation thresholds.

In the invention, the reactive composition of the liner comprises metalparticulates having different morphologies. More specifically, the linercomprises a compacted composition comprising a spherical metalparticulate and a non-spherical metal particulate. One advantage ofusing a mixture of spherical and non-spherical particulates,particularly spherical and flaked particulates, is that the activationenergy or externally applied pressure required to initiate anintermetallic reaction is reduced compared to mixtures which compriseonly spherical metal particulates. Another advantage is that theintermetallic reaction is more likely to go to completion and hence, theexothermic energy output of the liner is increased. A yet furtheradvantage is that the material of the reactive liner is typicallyconsumed such that there is no slug of liner material left in the holethat has just been formed. (The slug that is left behind, withnon-reactive liners, may create a yet further obstruction to the flow ofoil and/or gas from the well completion.)

In the interests of clarity, the compacted particulate composition is aparticulate composition comprising a spherical metal particulate and anon-spherical metal particulate which has been compacted (i.e. thespherical and non-spherical particles have been compacted together). Itwill be understood that the compaction process may cause somedeformation of the component particulates, such that the spherical metalparticulate—for example—becomes slightly aspherical. However, the aspectratio of the non-spherical particulate remains greater than that of thespherical particulate.

The particulates may be of any commonly used size of particulate incompacted metal liners such as, for example, micron, sub-micron or evennanosized powders, provided that the non-spherical metal particulateshave a greater aspect ratio than the spherical metal particulates. Inthe case of the non-spherical particulates, one or more dimensions maybe of a different size order to one or more other dimensions. By way ofillustration, the non-spherical particulate may be a flake having planedimensions of the order (say) 100×50 microns, but the thickness may benanometric (say around 1 nm).

By the term “aspect ratio” is meant the ratio of its longer or longestdimension to its shorter or shortest dimension.

By the term “spherical particulate” is meant a particulate that isproduced by standard manufacturing methods as a spherical ornear-spherical particulate. This may include, for example, an oblatespheroid.

Preferably, the spherical particulates have a diameter which is lessthan that of the average longest dimension of the non-spherical metalparticulate. In a preferred arrangement, the spherical particulates havean average diameter of 50 microns or less, more preferably 25 microns orless and most preferably in the range of from 5 microns to 20 microns.Preferably, the average longest dimension of the non-spherical metalparticulate is at least twice the diameter of the spherical particulate.

Preferably, the non-spherical metal is selected from a flaked,rod-shaped or ellipsoid particulate, more preferably a flakedparticulate. In a preferred arrangement, the non-spherical particulateis a flaked particulate and preferably has an aspect ratio of less than500:1, more preferably less than 300:1, even more preferably has anaspect ratio in the range of from 10:1 to 300:1, and most preferably hasan aspect ratio in the range of 50:1 to 200:1. Preferably, thenon-spherical metal particulate has an average longest dimension of lessthan 300 micron, more preferably an average longest dimension in therange of 2 micron to 50 micron.

The skilled person will realize that the term “flake” is generally meansa flat, thin piece of material. In the invention, the flake may have anyconvenient regular or irregular shape, preferably a regular shape suchas a square, rectangular, disc, oval or leaf shape. A rectangular orsquare flake is most preferred. Preferably, but not necessarily, theflaked particles are planar or near-planar.

Preferably, the more malleable metal out of the at least two metals isselected as the spherical particulate. This is because the inventorshave found that, upon detonation, the compression caused by the shockwave provides better particle mixing and hence, a higher probability ofreaction. For this reason, aluminium, when present in the reactivecomposition, is generally preferred as the spherical particulate.

The liner may further comprise at least one further inert metal which issubstantially inert with respect to the rest of the reactivecomposition, the further metal preferably being present in an amountgreater than 10% w/w of the liner. More preferably, the at least onefurther metal is present in an amount greater than 20% w/w of the liner,even more preferably greater than 40% w/w of the liner. In a yet furtherpreferred option, the further metal is present in the range of from 40%to 95% w/w of the liner, more preferably in the range of from 40% to 80%w/w, yet more preferably 40% to 70% w/w of the liner. The percentageweight for weight w/w is with respect to the total composition of theliner.

The at least one further metal may be considered as being substantiallynon-reactive or substantially inert with respect to the rest of thereactive composition. By the term, “substantially inert” we mean thatthe further metal possesses only a reduced energy of formation with thereactive composition (if indeed any) compared with the energy offormation between the non-spherical and spherical particulates that formthe reactive composition.

The at least one further metal is preferably selected from a highdensity metal. Particularly suitable metals are copper or tungsten, oran admixture thereof, or an alloy thereof. The at least one furthermetal is preferably mixed and uniformly dispersed within the reactivecomposition to form an admixture. Alternatively, the liner mayadditionally comprise a layer of at least one further metal, said layertypically being covered by a layer of the reactive composition. Thelayers can then be pressed to form a consolidated or compacted liner byany known pressing techniques.

Reaction between aluminium (for example) and the at least one furthermetal (such as, for example, tungsten or copper) is likely to be lessfavourable and less exothermic than the reaction between the aluminiumand a flaked metal particulate (such as nickel or palladium) and istherefore not likely to be the main product of such a reaction. It willbe clear to the skilled person, however, that although the reactionbetween the at least one further metal and aluminium is less favourable,there may still be a trace amount of such a reaction product observedupon detailed investigation.

As discussed above, the spherical metal particulate and thenon-spherical metal particulate are together capable of an exothermicreaction to form an intermetallic compound, upon detonation of anassociated shaped charge device. Accordingly, the respective metals areselected such that, when supplied with sufficient energy (i.e. an amountof energy in excess of the activation energy to cause the exothermicreaction), the metal particulates will react to produce a large amountof energy, typically in the form of heat.

The use of non-stoichiometric amounts of the spherical particulates andnon-spherical metals particulates will provide an exothermic reaction.However, such a composition may not furnish the optimal amount ofenergy. In a preferred embodiment, the exothermic reaction of the lineris achieved by using a substantially stoichiometric (molar) mixture ofat least two metals. The at least two metals are preferably selectedsuch that they produce, upon activation of the shaped charge liner, anelectron compound, with an accompanying release of heat and/or light.The reaction typically involves only two metals, although intermetallicreactions involving more than two metals are known and not excluded fromthe invention.

There are many different electron compounds (also know as intermetallicelectron compounds or electron intermetallic compounds) that may beformed. Conveniently, these compounds may be grouped as Hume-Rotherycompounds. Electron compounds are typically formed by high melting pointmetals (for example Cu, Ag, Au, Fe, Co, Ni) reacting with lower meltingpoint metals (for example Cd, Al, Sn, Zn, Be). The Hume-Rotheryclassification identifies an intermetallic compound by means of itsvalence electron concentration, i.e. the ratio of valence electrons toatoms (N_(E):N_(A)) taking part in the chemical bond. Typically, thiscan be expressed as the quotient of simple integers. Example ratios are3/2, 7/4 and 21/13.

Preferably, in the invention, the at least two metals are selected toproduce a Hume-Rothery intermetallic compound and more preferably, theat least two metals are selected to produce, in operation, intermetalliccompounds which possess electron to atom ratios selected from 3/2, 7/4,9/4 and 21/13. The reactive liner of the invention gives particularlyeffective results when the two metals (i.e. the spherical metalparticulate and the non-spherical metal particulate) are provided inrespective proportions calculated to give an electron atom ratio of 3/2,7/4, 9/4 or 21/13, more preferably a ratio of 3 valency electrons to 2atoms. Most preferably, the reactive composition comprises two metalswhich can react to form a Hume-Rothery compound having an electron toatom ratio of 3/2.

Accordingly, advantageous exothermic energy outputs can be achieved inthe invention using stoichiometric compositions such as Co—Al, Fe—Al,Pd—Al, CuZn, Cu₃Al, C₅Sn and Ni—Al (all of which have an electronconcentration of 3/2). Aluminium-based compositions are particularlysuitable because Al is a cheap, readily available material. Preferably,but not necessarily, the aluminium is a spherical particulate and theother metal is a non-spherical, preferably flaked, material. Morepreferred compositions are nickel and aluminium, or palladium andaluminium, preferably mixed in stoichiometric quantities. The aboveexamples, when they are forced to undergo a reaction, provide excellentthermal output and, in the case of nickel, iron and aluminium, arerelatively cheap materials. The most preferred composition is Ni—Al.

By way of example, important benefits are observed for a NiAl lineraccording to the invention. Using a uniaxial strain test system, it hasbeen demonstrated that, when both metals are present as spherical metalparticulates, the liner reacts only when subjected to a peak reflectedpressure of >˜14 GPa. This figure is reduced to around 6 GPa forspherical aluminium and flaked nickel. One advantage of using a lowerthreshold pressure to cause the intermetallic reaction (whichcorresponds to a lower activation energy for the triaxial stress systemof a shaped charge) is ensuring that a greater percentage of thereaction goes to completion. A yet further advantage of a lowerthreshold pressure is that a lower output explosive may be used toproduce the same effect. This is particularly beneficial for liners forsmall shaped charges (i.e. shaped charges having a diameter of less thanabout 32 mm), particularly for liners where the liner thickness beginsto represent a significant portion of the size of the particles.

Preferably, the reactive composition comprises aluminium and at leastone metal with which aluminium exothermically reacts to form anintermetallic compound. More preferably, the reactive compositioncomprises aluminium and at least one metal selected from the groupconsisting of Ce, Fe, Co, Li, Mg, Mo, Ni, Nb, Pb, Pd, Ta, Ti, Zn and Zr,more preferably from the group consisting of Ce, Fe, Co, Li, Mg, Ni, Pb,Pd, Ti, Zn and Zr, and most preferably from the group consisting of Fe,Co, Ni and Pd, in combinations which are known to produce an exothermicevent when mixed. The aluminium may be provided as a sphericalparticulate, and the at least one metal as a non-spherical particulate,or vice versa.

In one preferred embodiment the liner composition comprises sphericalaluminium and at least one flaked metal particulate. When supplied withsufficient energy (i.e. an amount of energy in excess of the activationenergy to cause the exothermic reaction) the composition reacts toproduce a large amount of energy, typically in the form of heat. Theenergy to initiate the electron compound (i.e. intermetallic) reactionis supplied by the detonation of the high explosive in the shaped chargedevice.

In the preferred embodiment, the non-spherical metal may be selectedfrom metals in any one of Groups VIIIA, VIIA, VIA, IIB and 1B of theperiodic classification. Preferably, the metal is selected from GroupVIIIA VIIA and IIB, more preferably Group VIIIA. Ideally, thenon-spherical metal is selected from the Group consisting of iron,cobalt, nickel and palladium.

The liner may be prepared by any suitable method, for example bypressing the composition to form a green compact. It will be obviousthat any mechanical or thermal energy imparted to the reactive materialduring the formation of the liner must be taken into consideration so asto avoid an unwanted exothermic reaction. Preferably, the liner is anadmixture of particulates of the reactive composition and the at leastone further metal. Preferably, the liner is formed by pressing theadmixture of particulates, using known methods, to form a pressed (alsoreferred to as a compacted or consolidated) liner.

In the case of pressing the reactive composition to form a greencompacted liner, a binder may be required. The binder may be a powderedsoft metal or non-metal material. Preferably, the binder comprises apolymeric material such as PTFE or an organic compound such as astearate, wax or epoxy resin. Alternatively, the binder may be selectedfrom an energetic binder such as Polyglyn (Glycidyl nitrate polymer),GAP (Glycidyl azide polymer) or Polynimmo(3-nitratomethyl-3-methyloxetane polymer). The binder may also be ametal stearate, such as, for example, lithium stearate or zinc stearate.

Conveniently, the spherical particulates and/or the non-sphericalparticulates and/or the further metal which forms part of the linercomposition is coated with one of the aforementioned binder materials.Typically, the binder, whether it is being used to pre-coat a metal oris mixed directly into the composition containing a metal, is present inthe range of from 1% to 5% by mass.

Advantageously, if the longest dimension of the spherical particulatesand the non-spherical particulates (such as, for example, nickel andaluminium, or iron and aluminium, or palladium and aluminium) in thecomposition of a reactive liner is less than 10 microns, and even morepreferably less than 1 micron, the reactivity and hence the rate ofexothermic reaction of the liner will be further increased. In this way,a reactive composition formed from readily available materials, such asthose disclosed earlier, may provide a liner which possesses not onlythe kinetic energy of the cutting jet, as supplied by the explosive, butalso the additional thermal energy from the exothermic chemical reactionof the composition.

At particle diameter sizes of less than 0.1 micron, the metals in thereactive composition become increasingly attractive as a shaped chargeliner material due to their even further enhanced exothermic output onaccount of higher relative surface area of the reactive compositions. Ayet further advantage of decreasing particle diameter is that, as theparticle size of the at least one further metal decreases, the actualdensity that may be achieved upon consolidation increases. As particlesize decreases, the actual consolidated density that can be achievedstarts to approach the theoretical maximum density for the at least onefurther metal.

The reactive liner thickness may be selected from any known or commonlyused wall liner geometries thickness. The liner wall thickness isgenerally expressed in relation to the diameter of the base of the linerand is preferably selected in the range of from 1 to 10% of the linerdiameter, more preferably in the range of from 1 to 5% of the linerdiameter. In one arrangement, the liner may possess walls of taperedthickness, such that the thickness at the liner apex is reduced comparedto the thickness at the base of the liner. Alternatively, the taper maybe selected such that the apex of the liner is substantially thickerthan the walls of the liner towards its base. A yet further alternativeis where the thickness of the liner is not uniform across its surfacearea or cross section; for example, a conical liner in cross sectionwherein the slant/slope comprises blended half angles scribed about theliner axis to produce a liner of variable thickness.

The shape of the liner may be selected from any known or commonly usedshaped charge liner shape, such as substantially conical, tulip, trumpetor hemispherical.

According to a further aspect of the invention there is provided areactive oil and gas well shaped charge perforator liner comprising acompacted particulate reactive composition, said composition comprisingan aluminium particulate and at least one metal particulate, wherein theaspect ratio of the at least one metal particulate is greater than thealuminium particulate. By reactive, we mean that the aluminiumparticulate and the at least one metal particulate are together capableof an exothermic reaction to form an intermetallic compound, upondetonation of an associated shaped charge device.

Preferably, the composition comprises two metals that are capable of anexothermic reaction, the first metal being selected from aluminium andthe second metal being selected from any one of Groups VIIIA, VIIA andIIB, wherein the aspect ratio of the second metal particulate is greaterthan the aluminium particulate.

Another aspect of the invention provides a method of producing areactive shaped charge liner, said method comprising the steps ofproviding a composition of at least two metals and compacting saidcomposition to form a liner, wherein the composition comprises aspherical metal particulate and a non-spherical metal particulate. Byreactive is meant that the spherical metal particulate and thenon-spherical metal particulate are together capable of an exothermicreaction to form an intermetallic compound, upon detonation of anassociated shaped charge device.

According to a yet further aspect of the invention there is provided theuse of a reactive composition in an oil and gas well shaped chargeperforator liner, said reactive composition comprising at least twometals wherein the liner is a compacted particulate compositioncomprising a substantially spherical metal particulate and anon-spherical metal particulate.

There is also provided a method of improving fluid outflow from an oilor gas well comprising the step of using a reactive liner according tothe invention. Preferably, the energy from the intermetallic reaction(i.e. from the liner) is imparted to the saturated substrate of a well.

There is further provided a compacted particulate reactive compositionsuitable for use in a shaped charge liner, said composition comprisingaluminium and at least one metal that undergoes an exothermicintermetallic reaction with aluminium, wherein the aspect ratio of theat least one metal particulate is greater than that of the aluminiumparticulate. In operation, the composition provides thermal energy uponactivation of an associated shaped charge, the thermal energy beingimparted to the saturated substrate of the well.

A further aspect of the invention comprises a shaped charge suitable fordown hole use comprising a housing, a quantity of high explosive and aliner as described hereinbefore located within the housing, the highexplosive being positioned between the liner and the housing.

Preferably, the housing is made from steel, although the housing couldinstead be formed partially or wholly from one of the reactive linercompositions as hereinbefore defined, preferably by one of theaforementioned pressing techniques. In the latter case, upon detonation,the case will be consumed by the reaction. Advantageously, this reducesthe likelihood of the formation of fragments. If fragments are notsubstantially retained by the confines of the perforating gun, they maycause a further obstruction to the flow of oil or gas from the wellcompletion.

The high explosive may be selected from a range of high explosiveproducts such as RDX, TNT, RDX/TNT, HMX, HMX/RDX, TATB, HNS. It will bereadily appreciated that any suitable energetic material classified as ahigh explosive may be used in the invention. Some explosive types arehowever preferred for oil well perforators, because of the elevatedtemperatures experienced in the well bore.

The diameter of the liner at the widest point, that being the open end,can either be substantially the same diameter as the housing, such thatit would be considered as a full calibre liner or alternatively theliner may be selected to be sub-calibre, such that the diameter of theliner is in the range of from 80% to 95% of the full diameter. In atypical conical shaped charge with a full calibre liner the explosiveloading between the base of the liner and the housing is very small,such that in use the base of the cone will experience only a minimumamount of loading. Therefore in a sub calibre liner a greater mass ofhigh explosive can be placed between the base of the liner and thehousing to ensure that a greater proportion of the base liner isconverted into the cutting jet.

The depth of penetration into the well completion is a critical factorin well completion engineering, so it is usually desirable to fire theperforators perpendicular to the casing to achieve the maximumpenetration, and—as highlighted in the prior art—typically alsoperpendicular to each other to achieve the maximum depth per shot. Itmay be desirable to locate and align at least two of the perforatorssuch that the cutting jets will converge, intersect or collide at ornear the same point. In an alternative embodiment, at least twoperforators are located and aligned such that the cutting jets willconverge, intersect or collide at or near the same point, wherein atleast one perforator is a reactive perforator as hereinbefore defined.The phasing of perforators for a particular application is an importantfactor to be taken into account by the completion engineer.

The perforators as hereinbefore described may be inserted directly intoany subterranean well completion. However, it is usually desirable toincorporate the perforators into a perforation gun, in order to allow aplurality of perforators to be deployed into the well completion.

According to a further aspect of the invention there is provided amethod of completing an oil or gas well using one or more shaped chargeperforators, or one or more perforation guns as hereinbefore defined.

It will be understood by the skilled man that inflow is the flow offluid, such as, for example, oil or gas, from a well completion.

Conveniently, improvement of fluid inflow may be provided by the use ofa reactive liner which reacts to produce a jet with a temperature inexcess of 2000 K, such that in use said jet interacts with the saturatedsubstrate of an oil or gas well, causing increased pressure in theprogressively emerging perforator tunnel. In a preferred embodiment, theoil or gas well is completed under substantially neutral balancedconditions. This is particularly advantageous as many well completionsare performed using under balanced conditions to remove the debris formthe perforated holes. The generation of under balance in a wellcompletion requires additional equipment and expense. Conveniently, theimprovement of inflow of the oil or gas well may be obtained by usingone or more perforators or one or more perforation guns as hereinbeforedefined.

Accordingly, there is further provided an oil and gas well perforationsystem intended for carrying out the method of improving inflow from awell comprising one or more perforation guns or one or more shapedcharge perforators as hereinbefore defined.

According to a further aspect of the invention there is provided the useof a reactive liner or perforator as hereinbefore defined to increasefracturing in an oil or gas well completion for improving the inflowfrom said well.

A yet further aspect of the invention provides the use of a reactiveliner or perforator or perforation gun as hereinbefore defined to reducethe debris in a perforation tunnel. The reduction of this type of debrisis commonly referred to, in the art, as clean up.

According to a further aspect of the invention there is provided amethod of improving inflow from a well comprising the step ofperforating the well using at least one liner, perforator, orperforation gun according to the present invention. Inflow performanceis improved by virtue of improved perforations created, that is largerdiameter, greater surface area at the end of the perforation tunnel andcleaned up holes, holes essentially free of debris.

Previously in the art, in order to create large diametertunnels/fractures in the rock strata, big-hole perforators have beenemployed. The big-hole perforators are designed to provide a large hole,with a significant reduction in the depth of penetration into thestrata. Engineers can use combinations of big-hole perforators andstandard perforators to achieve the desired depth and volume.Alternatively, tandem devices liners have been used which incorporateboth a big-hole perforator and standard perforator. This typicallyresults in fewer perforators per unit length in the perforation gun andmay cause less in-flow. Big hole perforators can also be used incomminuted powder formations in combination with a sand screen to avoidin-flow after perforation of the loose sand/powder.

Advantageously, the reactive liners and perforators hereinbefore definedgive rise to an increase in penetrative depth and volume, using only oneshaped charge device. A further advantage is that the reactive linersaccording to the invention performs the dual action of depth anddiameter (i.e. hole volume) and so there is no reduction in explosiveloading or reduction in numbers of perforators per unit length.

Any feature in one aspect of the invention may be applied to any otheraspects of the invention, in any appropriate combination. In particular,device aspects may be applied to method and/or use aspects, and viceversa.

DESCRIPTION OF THE DRAWINGS

In order to assist in understanding the invention, a number ofembodiments thereof will now be described, by way of example only andwith reference to the accompanying drawing, in which:

FIG. 1 is a cross-sectional view along a longitudinal axis of a shapedcharge device containing a liner according to the invention;

FIG. 2 is a sectional view of a well completion in which a perforatoraccording to an embodiment of the invention may be used;

FIG. 3 is a schematic representation of an explosive anvil system usedto test reactive compositions for use in the liner of the invention; and

FIG. 4 is an XRD trace for a non-spherical/spherical NiAl particulatecomposition tested in the system of FIG. 3.

DESCRIPTION OF THE INVENTION

FIG. 1 is a cross-sectional view of a shaped charge, typicallyaxially-symmetric about centre line 1, of generally conventionalconfiguration comprising a substantially cylindrical housing 2 producedfrom a metal (usually, but not exclusively, steel), polymeric, GRP orreactive material according to the invention. The liner 6 according tothe invention has a wall thickness of typically 1 to 5% of the linerdiameter, but may be as much as 10% in extreme cases and to maximizeperformance is of variable liner thickness. The liner 6 fits closelyinto the open end 8 of the cylindrical housing 2. High explosivematerial 3 is located within the volume enclosed between the housing andthe liner. The high explosive material 3 is initiated at the closed endof the device, proximate to the apex 7 of the liner, typically by adetonator or detonation transfer cord which is located in recess 4.

One method of manufacture of liners is by pressing a measure ofintimately mixed and blended powders in a die set to produce thefinished liner as a green compact. Alternatively, intimately mixedpowders may be employed in the same way as described above, but thegreen compacted product is a near net shape allowing some form ofsintering or infiltration process to take place.

Modifications to the invention as specifically described will beapparent to those skilled in the art, and are to be considered asfalling within the scope of the invention. For example, other methods ofproducing a fine grain liner will be suitable.

With reference to FIG. 2, there is shown a stage in the completion of awell 21 in which the well bore 23 has been drilled into a pair ofproducing zones 25, 27 in, respectively, unconsolidated and consolidatedformations. A steel tubular casing 9 is cemented within the bore 23. Inorder to provide a flow path from the production zones 25, 27 into theannulus that will eventually be formed between the casing 9 andproduction tubing (not shown) which will be present within the completedwell, it is necessary to perforate the casing 9. In order to formperforations in the casing 9, a gun 11 is lowered into the casing on awireline, slickline or coiled tubing 13, as appropriate. The gun 11 is agenerally hollow tube of steel comprising ports 15 through whichperforator charges of the invention (not shown) are fired.

EXAMPLES

Experiments were conducted to compare the reactive behaviour of thefollowing samples, using similar initial density and shock loadingconditions:

-   -   a NiAl composition comprising a 1:1 molar ratio of spherical Ni        particulates and spherical Al particulates, each of size 7-15        micron.    -   a NiAl composition comprising a 1:1 molar ratio of flaked Ni        particulates (44 micron by 0.37 micron, aspect ratio 119:1) and        spherical Al particulates (5-15 micron).

The TMD of all tests samples was about 60%.

Referring to FIG. 3, an explosive anvil system 30 was used to test thesamples, the system comprising a steel anvil 31, a steel cover plate 32,SX2 explosive 33 and an RP80 detonator 34. The sample to be tested wasplaced in recess 35 in anvil 31.

Initial tests were conducted using a 6 mm thickness of SX2. The skilledperson will realize that thresholds depend on the type of shock loadingand accordingly, the loadings quoted in respect of the anvil tests donot necessarily equate with the loading in a shaped charge.

The samples were subjected to shock and recovered for analysis. It wasfound that the Ni flake/Al sphere sample according to the invention hadundergone close to 100% reaction to form an intermetallic compound.X-ray diffraction (XRD) analysis confirmed that the main reactionproducts were NiAl and Ni₂Al₃, with traces of Ni₅Al₃ and Ni₃Al (see FIG.4).

In contrast, approximately 5% of the spherical Ni/spherical Al samplereacted to form an intermetallic compound. The test was repeated using a9 mm thickness of SX2. It was found that increasing the explosiveloading increased the extent of reaction to about 10%.

It can be concluded that, under identical loading conditions, a reactivecomposition comprising a spherical metal particulate and non-sphericalmetal particulate produces more energy. Conversely, a desired energyoutput can be obtained at a lower detonation threshold. It follows thata shaped charge liner according to the invention provides similarbenefits. For small charges in particular, liners according to theinvention can be used to maximize the volume of the shaped charge jet athigh temperature, thereby ensuring that more thermal work is put intothe target.

It will be understood that the present invention has been describedabove purely by way of example, and modification of detail can be madewithin the scope of the invention. Each feature disclosed in thedescription and (where appropriate) the claims and drawings may beprovided independently or in any appropriate combination.

1. A method of using a compacted particulate reactive composition in anoil and gas well shaped charge perforator liner, the reactivecomposition being a composition of at least two metals and comprising asubstantially spherical metal particulate and a non-spherical metalparticulate.
 2. The method of claim 1, further comprising: placing theshaped charge perforator liner within a housing of a shaped chargeperforator; providing a high explosive material between the shapedcharge perforator liner and the housing; positioning the shaped chargeperforator in a saturated substrate of an oil or gas well; detonatingthe high explosive material; in response to detonating the highexplosive material: causing an exothermic reaction of the compactedparticulate reactive composition; producing an electron compound; andforming, from the compacted particulate reactive composition, a highvelocity jet of material to penetrate into a well casing of the oil orgas well.
 3. The method of claim 2, wherein the spherical metalparticulate comprises aluminium, wherein the exothermic reactioninvolves an interaction between the non-spherical metal particulate andthe aluminium, wherein the aspect ratio of the non-spherical metalparticulate is greater than that of the aluminium, and wherein theshaped charge perforator liner comprises a threshold pressure of 6 GPaor less to cause the exothermic reaction.
 4. The method of claim 2,further comprising: perforating the well casing of the oil or gas wellso as to improve inflow from the oil or gas well.
 5. The method of claim2, wherein producing the electron compound comprises producing aHume-Rothery compound.
 6. The method of claim 2, wherein the housing isformed partially or wholly from a reactive composition, wherein thereactive composition comprises the composition of the shaped chargeperforator liner; wherein the method further comprises: consuming thehousing by the exothermic reaction.
 7. The method of claim 2, whereinpositioning the shaped charge perforator comprises positioning theshaped charge perforator in a down hole configuration.
 8. The method ofclaim 2, wherein positioning the shaped charge perforator comprisespositioning the shaped charge perforator such that, upon detonation, thehigh velocity jet of material expands substantially perpendicular to asidewall of the well casing.
 9. The method of claim 1, wherein thecompacted particulate reactive composition comprises a substantiallystoichiometric mixture of the at least two metals.
 10. The method ofclaim 1, further comprising: coupling a plurality of shaped chargeperforator liners within respective housings of respective shaped chargeperforators; providing a high explosive material between the respectiveshaped charge perforator liners and their respective housings;positioning the plurality of shaped charge perforators within aperforator gun; positioning the perforator gun in a saturated substrateof an oil or gas well; detonating the respective high explosivematerials; in response to detonating the high explosive materials:causing an exothermic reaction of the compacted particulate reactivecomposition; producing an electron compound; and forming, from thecompacted particulate reactive composition, high velocity jets ofmaterial that penetrate into a well casing of the oil or gas well. 11.The method of claim 10, wherein positioning the plurality of shapedcharge perforators comprises positioning the plurality of shaped chargeperforators perpendicular to each other such that the respective highvelocity jets will converge, intersect or collide at or near the samepoint.
 12. A method of manufacturing a reactive shaped charge liner, themethod comprising: providing a composition of at least two metals; andcompacting the composition of at least two metals to form a liner,wherein the composition comprises a spherical metal particulate and anon-spherical metal particulate.
 13. The method of claim 12, whereincompacting the composition of at least two materials forms a greencompact.
 14. The method of claim 12, wherein compacting the compositionof at least two materials comprises compacting the composition of atleast two materials in a die set.
 15. The method of claim 12 whereincompacting the composition of at least two materials comprisescompacting the at least two materials into a near net shape so as toallow sintering or infiltration processes to take place, wherein thenear net shape provides for placement of the liner into a housing of ashaped charge perforator.
 16. The method of claim 12, furthercomprising: providing at least one other metal, wherein the at least oneother metal comprises a high density metal; and mixing and uniformlydispersing the high density metal within the composition.
 17. The methodof claim 12, further comprising: producing a layer of at least onefurther metal; covering the layer with a layer of the composition; andcompacting the layers to form a consolidated liner.
 18. The method ofclaim 12, further comprising: providing a binder material, wherein thebinder material is a powdered soft metal or a non-metal material; mixingthe binder material with the composition; and compacting the mixture ofthe binder material and the composition.
 19. A method of testing samplesof reactive liner materials for use in a method of improving fluidoutflow from an oil or gas well comprising: placing a test sample in anexplosive anvil system comprising a steel anvil, a steel cover plate, anexplosive, and a detonator, wherein the test sample is placed in arecess, subjected to shock, and recovered for analysis, wherein theanalysis comprises X-ray diffraction.
 20. The method of claim 19,wherein the test sample comprises a compacted particulate compositioncomprising a spherical metal particulate and a non-spherical metalparticulate.